A Lipped Box Lid

The easiest way to make a lidded box is to build the box and lid as one
piece and then cut them apart on the table saw. This guarantees that the
lid will be a perfect fit to the box. With a little modification, this same
technique can be used to make a box and lid that mate with interlocking
lips, as shown in the photo at right.

This technique for making a box lid is a little different in that you do
part of the job before the box is assembled. A look at the two drawings
will explain. To create the lip, you’ll need to cut halfway through
the sides from both the inside and the outside. As shown in Figure 1, the
inside cuts are made while the box is still in pieces. Remember that this
first cut will form the “high” side of the lip.

Once the box is assembled, you complete the job with a second series
“halfway” cuts that are offset a blade’s width (1/8″) from the first
(Figure 2). These cuts are positioned below the first cuts. If you hit it
right, the lid will separate cleanly and after a little sanding,
you’ll have a snug-fitting, lipped lid.